Closure for a container

ABSTRACT

A closure assembly for use on a container neck finish has an inner cap which threadedly engages the neck finish and an outer cap which is received by the inner cap. Torque lugs on the outer cap cooperate with abutment formations on the inner cap such that rotation of the outer cap drives the inner cap onto the neck finish. Cooperative engagement between the two caps is achieved by downward axial movement of the outer cap. An arrangement of ramp sections on the inner cap and an arrangement of interior lugs on the outer cap provide an assist feature helping to pull the outer cap in the axially downward direction. Another feature of the closure assembly includes a spring-biasing relationship between the inner and outer caps. The inner cap also includes an abutment structure which cooperates with the container to limit drop test deformation of the container.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of PCT Application No. PCT/US2014/063816, filed Nov. 4, 2014 which claims the benefit of U.S. Provisional Patent Application Ser. No. 61/905,488 filed Nov. 18, 2013, both of which are hereby incorporated by reference.

BACKGROUND

One construction for a child-resistant (CR) closure is to use a combination of an inner cap and a cooperating outer cap. When the neck finish of the corresponding container is externally threaded, the inner cap is typically constructed and arranged with internal threads which allow the inner cap to be securely assembled, by threading, onto the neck finish. Although other connection constructions between the inner cap and the container neck finish might be contemplated, the exemplary embodiment disclosed herein shows a threaded connection.

In order to incorporate a child-resistant feature or capability to this inner and outer cap construction, an engagement between these two caps is used. The manner or method of engagement in order to be able to remove the inner cap from the container involves a particular movement and manipulation of the two caps which is considered difficult for a child to perform. It is unlikely that a child will be able to perform the required manipulation in order to open the container.

When the container is used for dry material of a particulate form, the child-resistant capability may be satisfied by simply preventing complete removal of the inner cap by a child. However, when a liquid product is in the container, it is important that the closed condition between the inner cap and the container not be defeated by a child while playing with or manipulating the inner and outer caps. Maintaining a seal is important when a liquid product is present. When an intended user desires to open the container, the outer cap is used to engage the inner cap such that the inner cap is able to be removed from the neck finish of the container.

At the time of initial capping of the container by threaded engagement of the inner cap, referring now to the exemplary embodiment, the inner and outer caps are already preassembled together as a two-cap closure subassembly. This two-cap subassembly is then driven onto the container neck finish as a unit. Typically, the outer cap is gripped in some manner and it is the outer cap which drives the inner cap into threaded assembly onto the container neck finish. In order to achieve a reliable assembly of the inner cap onto the neck finish and in order to do so in an efficient manner, the specific structures of the inner cap and the outer cap become important. These specific structures must also be considered relative to the removal procedure or steps in order to unscrew the inner cap from the neck finish and thereby be able to open the container. A more complicated removal procedure relative to what a child would likely be capable of performing is called for when making the closure child-resistant (CR).

A further consideration in the design of a CR closure is what type of automated capping equipment might be used. Manual application of the inner cap onto the neck finish by way of the outer cap, such as when reclosing the container, is fairly easy to perform if the inner cap to outer cap engagement is secure and reliable. When automated equipment is used for the capping operation, the sensory and tactile feedback to a human cannot be duplicated.

When automated capping equipment is to be used, gripping of the outer cap in order to drive the inner cap must be carefully designed such that gripping distortion and over-tightening do not result. These consequences must be considered in the design of the equipment and in the manner that the equipment grips onto the outer cap. While machine torque settings can be used to presumably resolve any over-tightening issues, the safe gripping of the outer cap may be more challenging. One option is to shape the outside diameter or outer surface of the outer cap in a unique manner for interfit with the automated capping equipment. If the automated capping equipment uses some type of sleeve, shroud or chuck which fits over and around the outer cap, then this two-cap closure subassembly can be properly moved and manipulated for the automated capping. The unique contouring of the outer surface of the outer cap also provides an improved grip for manual removal and re-closing of the inner cap onto the neck finish of the container.

Considering current inner cap and outer cap combinations, improvement in their construction and in their relationship to one another is contemplated by the present invention.

SUMMARY

A child-resistant (CR) closure for assembly to the neck finish of a container includes an inner cap and a cooperating outer cap. The inner cap is constructed and arranged to thread onto the neck finish of a container and the outer cap engages the inner cap, initially forming a two-component closure subassembly. By using the outer cap as the driving cap for the inner cap (i.e. the driven cap), the inner cap is able to be threaded onto the neck finish and removed from the neck finish. In order to perform either action, the outer cap must securely engage the inner cap in some fashion and the manner of engagement must, at least in some fashion, be reversible so that the inner cap can both be applied to the neck finish and removed from the neck finish.

Although the inner cap and outer cap are pre-assembled as a two-cap subassembly, engagement between the two caps for the purpose of driving the inner cap onto the container neck finish requires some degree of downward axial travel of the outer cap relative to the inner cap. The fact that downward axial travel is required indicates that the inner cap and outer cap are not yet engaged in the desired manner such that the outer cap is capable of driving the inner cap into tight threaded engagement on the neck finish. “Downward” in this context refers to axially moving the outer cap in the direction of the inner cap. When manually removing the inner cap from the neck finish of the container, the outer cap needs to be moved in this axially downward direction causing first torque lugs on the inner (upper) surface of the outer cap to interfit between second torque lugs on the outer (upper) surface of the inner cap. This interfit of cooperating sets of torque lugs provides a secure and reliable engagement for rotationally driving the inner cap by use of the outer cap. The engagement of these first and second torque lugs, noting that there is a plurality of each style in a uniform and repeating pattern, occurs in either a clockwise (CW) direction of rotation as well as in a counterclockwise (CCW) direction of rotation.

Whether using the outer cap to advance the inner cap into threaded engagement of the neck finish or for retrograde movement to remove the inner cap from the neck finish, downward axial movement of the outer cap is required. The outer cap includes a type of spring biasing structure whereby the resistive force acting against downward travel of the outer cap increases as the outer cap gets closer to the inner cap in terms of downward axial movement. While this spring biasing force is only light to moderate, it does provide a relationship between the inner cap and outer cap which facilitates the use contemplated for this two-cap combination.

The CR feature disclosed herein pertains to the efforts to control removal of the inner cap from the neck finish. When advancing the inner cap onto the neck finish, during either original capping or when closing the container after use, there is no need for any CR capability. Accordingly, the downward axial travel of the outer cap when applying the inner cap to the neck finish can be less and thus less resistive force compared to removal of the inner cap from the neck finish. Increasing the required degree or extent of downward axial travel for the CR capability is desirable because the increase in movement and the moderate or slight increase in resistive force makes the opening of the container more challenging for a child than simply closing the container.

In furtherance of the difference in downward axial travel and the resulting, albeit slight, difference in the force level, the engagement between the inner cap and the outer cap utilizes a circumferential ramp structure in order to provide a torque assist when threading the inner cap onto the neck finish. This torque assist feature exists when unthreading the inner cap from the neck finish. However, the degree of assistance is less when unthreading as compared to threading. These torque-assist ramp structures located around the lower portion of the inner cap sidewall cooperate with a special form for each of the first torque lugs. The axial thickness of each of the first torque lugs gradually increases from the trailing edge to the leading edge in a clockwise direction. In other words, when the first torque lugs are used to engage the second torque lugs and utilize the outer cap to drive the inner cap, the leading edge of each first torque lug is axially thicker than its trailing edge. As a result, there is less downward axial travel required in order to reach a point where the first torque lugs engage the second torque lugs. This engagement is by means of surface to surface abutment using the leading edge or surface of each first torque lug to push against and drive each second torque lug. In the opposite direction of rotation, in this case counterclockwise rotation, the thinner edge of each first torque lug becomes the leading edge for abutment engagement with a corresponding one of the second torque lugs. In order to achieve this abutment engagement, additional downward axial travel of the outer cap relative to the inner cap is required. In other words, the first torque lugs need to be pushed further down toward the inner cap in order for abutment engagement to occur. The torque assist feature using the ramp structures which are part of the outer wall or outer skirt portion of the inner cap and the variation in axial thickness between the leading edge and trailing edge of each first torque lug are two improvements provided by the present invention according to the exemplary embodiment. In an alternate embodiment, the first torque lugs have a substantially uniform thickness.

Another design consideration for the type of CR closure disclosed herein relates to a Department of Transportation (DOT) drop test requirement which must be satisfied. The drop test specifies a height and a worst condition of an upper edge or corner impact. When the style of container disclosed herein is subjected to this drop test, it is possible for the axial upper end of the neck finish of the container to deform to the degree that permanent distortion results and container leakage is likely as a consequence of that distortion. Part of the issue is the thinner wall of the upper portion of the neck finish as compared to the thicker wall of the axially lower portion of the neck finish which provides the external threads. In order to limit the degree of distortion, the inner cap includes a radially-inwardly-directed abutment protrusion as part of the sidewall. This protrusion is either part-annular in segments or may be continuous. This protrusion part of the sidewall extends inwardly and it's inside diameter is smaller than the major diameter of the external threads. When the inner cap is fully threaded onto the neck finish, this protrusion is positioned adjacent a transition region between the upper portion of the neck finish (the thinner wall portion) and the lower portion of the neck portion (the thicker wall portion). This protrusion provides either an annular ring or a segmented annular ring around this transition region and in so doing provides an abutment surface or structure resisting the potential distortion of the neck finish. This protrusion limits the degree or extent of neck finish deformation and thereby precludes distortion to the point that leakage is likely.

Further features and improvements offered by the present invention will be described in conjunction with the description of the exemplary embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front elevational view of a container assembly according to an exemplary embodiment.

FIG. 2 is a front elevational view, in partial section, of the FIG. 1 container assembly.

FIG. 3 is a front elevational view of the FIG. 1 container assembly.

FIG. 4 is a partial, enlarged front elevational view of the neck finish of the FIG. 3 container.

FIG. 5 is a partial, enlarged front elevational view of the closure construction of the FIG. 2 illustration.

FIG. 6 is a front elevational view, in full section, of an inner cap and outer cap subassembly based on a first a cutting plane.

FIG. 7 is a front elevational view, in full section, of the FIG. 6 inner cap and outer cap subassembly based on a different cutting plane.

FIG. 8 is a front elevational view, in full section, of the inner cap and outer cap subassembly with a sealing liner added.

FIG. 9 is a perspective view of an inner cap comprising one component of the two-cap closure subassembly of FIG. 5.

FIG. 10 is a top plan view of the FIG. 9 inner cap.

FIG. 11 is a front elevational view of the FIG. 9 inner cap.

FIG. 12 is a bottom plan view of the FIG. 9 inner cap.

FIG. 13 is a front elevational view, in full section, of the FIG. 9 inner cap as viewed along line 13-13 in FIG. 10.

FIG. 14 is a front elevational view, in full section, of the FIG. 9 inner cap as viewed along line 14-14 in FIG. 10.

FIG. 15 is a perspective view of one embodiment of an outer cap comprising the other component of the two-cap closure subassembly of FIG. 5.

FIG. 16 is a top plan view of the FIG. 15 outer cap.

FIG. 17 is a top plan view of the FIG. 15 outer cap.

FIG. 18 is a bottom plan view of the FIG. 15 outer cap.

FIG. 19 is a front elevational view, in full section, of the FIG. 15 outer cap as viewed along line 19-19 in FIG. 16.

FIG. 20 is a front elevational view, in full section, of the FIG. 15 outer cap as viewed along 20-20 in FIG. 17.

FIG. 21 is a perspective view of another embodiment of an outer cap suitable for use in the two-cap closure subassembly of FIG. 5.

FIG. 22 is a front elevational view of the FIG. 21 outer cap.

FIG. 23 is a top plan view of the FIG. 21 outer cap.

FIG. 24 is a front elevational view, in full section, of the FIG. 21 outer cap as viewed along line 24-24 in FIG. 13.

FIG. 25 is a top plan view of the FIG. 21 outer cap.

FIG. 26 is a front elevational view, in full section, of the FIG. 21 outer cap as viewed along 26-26 in FIG. 25.

FIG. 27 is a bottom plan view of the FIG. 21 outer cap.

DESCRIPTION OF THE SELECTED EMBODIMENTS

For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications in the described embodiments, and any further applications of the principles of the invention as described herein are contemplated as would normally occur to one skilled in the art to which the invention relates. One embodiment of the invention is shown in great detail, although it will be apparent to those skilled in the relevant art that some features that are not relevant to the present invention may not be shown for the sake of clarity.

Referring to FIGS. 1-8, there is illustrated a closed container assembly 20 which is constructed and arranged to hold a liquid product. While the illustrated container is capable of holding virtually any product of a flowable nature, the focus herein is on a liquid product such that the inner cap which is disclosed must remain on the container neck finish in such a manner as to prevent leakage relative to any claim of being child-resistant (CR).

Assembly 20 includes a container 22, an inner cap 24 and a cooperating and engaging outer cap 26. The metal container 22 includes an externally threaded neck finish 28 which defines opening 30. The inner cap 24 is constructed and arranged with a series of internal thread 32 which cooperate with neck finish threads 34 for the secure assembly of the inner cap 24 onto the neck finish 28. In the exemplary embodiment, a sealing liner 35 is included. While this sealing liner could be included as part of the inner cap and outer cap subassembly prior to capping, the focus herein is on the two-cap combination whether or not a sealing liner 35 is included.

In the exemplary embodiment, the container 22 is fabricated out of a suitable metal and is used to hold a liquid product whose character indicates a need to include a child-resistant (CR) feature or capability as part of the inner cap 24 and outer cap 26 constructions for assembly 20. The neck finish 28 is constructed and arranged with a threaded portion 36, including neck finish threads 34, an extended spout portion 38 and a frustoconical transition portion 40 between portion 36 and portion 38. Each of these neck finish 28 portions is annular and generally concentric with each of the other portions. The manner of fabrication of the container and of the neck finish 28 results in the wall thickness of spout portion 38 being comparatively thinner than the wall thickness of threaded portion 36. This type of container assembly is subjected to a DOT drop test to see if any distortion or damage results, which might lead to leakage of the container assembly contents. Due to the different metal wall thicknesses, there is a greater likelihood of the spout portion deforming or distorting during drop testing. If the neck finish deforms or distorts to the degree or extent that leakage occurs, the construction will fail the required DOT testing.

Included as a part of the inner cap 24 construction (see FIGS. 9-14) is an annular abutment protrusion 42 which is part of sidewall 44. Protrusion 42 is preferably annular in form with an inside diameter which is smaller than the major diameter of threads 34. As protrusion 42 extends radially inwardly it is positioned adjacent transition portion 40 (see FIG. 5) when the inner cap 24 is fully threaded onto the neck finish 28. The construction and arrangement of this protrusion 42 will be explained in further detail as a part of the description of the inner cap 24. Protrusion 42 provides an annular ring around an inside surface of the inner cap. As an alternate construction, the protrusion may be segmented. When the inner cap 24 is fully threaded onto the neck finish 28, protrusion 42 is positioned at a location relative to the neck finish to help limit deformation and distortion of the neck finish which might result from a DOT drop test. Functionally what occurs is that this protrusion 42 serves as a barrier and as an abutment to limit and hopefully prevent any meaningful distortion or deformation of the neck finish to the extent or degree that leakage of the liquid contents would occur following the DOT drop test. Integral with protrusion 42 are six, equally-spaced, radially inwardly extending lugs 42 a. These lugs cooperate to help hold the optional liner 35 in place.

Referring now to FIGS. 9-14, the inner cap 24 is illustrated beginning with the perspective view of FIG. 9. Inner cap 24 is a unitary, single-piece, molded plastic component which includes an annular sidewall 44, an upper panel 46, a spoke structure 48 on the upper panel and a lower ring 50 formed with a plurality of equally-spaced, similarly-configured ramp portions 52.

In the exemplary embodiment, there are six ramp portions 52 and each ramp portion 52 includes a relief section 54 extending between points A and B. The first ramp section 56 extends between points A and C, moving in a CW direction. A second ramp section 58 extends between points B and D, moving in a CCW direction. Point D of one ramp portion 52 coincides with point C of the trailing ramp portion 52 when moving in a CW direction. As illustrated in FIG. 11, ramp section 56 is steeper than ramp section 58 which is flatter, with less incline. However, it is contemplated as part of an alternative embodiment that these two ramp sections could have the same incline.

The inner surface 60 of sidewall 44 is internally threaded with threads 32. The ribs 42 a are equally spaced axially above the threads. The protrusion 42 is also above the threads and extends radially inwardly beyond the threads 34. The sidewall includes a frustoconical section 62 which generally coincides with the location of the protrusion 42. This section 62 transitions into a generally cylindrical section 64 which surrounds upper panel 46. The spoke structure 48 includes six equally-spaced, outwardly radiating spokes 66. These individual spokes 66 constitute the second torque lugs as referenced above. The “hub” portion 68 surrounds a raised dome 70 (see FIGS. 13 and 14). The radial length of each spoke 66 extends close to the annular edge of the cylindrical section 64. Each spoke 66 has a uniform axial height or thickness.

The dome 70 cooperates with a projecting finger construction (projecting fingers 84) of the outer cap 26 in order to provide a spring-biased relationship between the inner cap 24 and the outer cap 26. One structural relationship for inner cap 24 which may not be immediately apparent is the circumferential location of each spoke 56 relative to the sections of each ramp portion 52. Related to this relationship is the cooperating relationship of the engaging portions (i.e. structural features) of the outer cap 26.

Referring now to FIGS. 15-20, a first embodiment of the outer cap is illustrated, beginning with the perspective view of outer cap 26 as shown in FIG. 15. Outer cap 26 has an octagonal outer surface with eight similarly shaped and equally-spaced panels or faces 71. This particular style of outer cap represents one of two cap embodiments disclosed herein. The second outer cap embodiment is illustrated in FIGS. 21-27. These two cap embodiments are functionally equivalent relative to their engagements over and around the inner cap 24. Regardless of the outer cap selection, the construction and arrangement of the inner cap does not change. For the most part, the interior or inner structures and features or these two outer cap embodiments are essentially the same. As such, the detailed description of outer cap 26 generally applies and is applicable to the other outer cap embodiment.

Outer cap 26 is a unitary, single-piece molded plastic component which includes an annular sidewall 72 and an upper panel 74. The sidewall 72 is constructed and arranged with an octagonal shape including the eight faces 71. Each face 71 is bounded by a vertical rib structure 73 which provides a unique ornamental appearance. Some type or style of surface contouring or shaping of the sidewall 72 can be used by automated capping equipment as a way to grip or chuck onto the outer cap 26 in order to drive the inner cap 24 for the initial assembly of the inner cap 24 onto the neck finish 28.

The sidewall 72 has an axially lower edge 76. The inside surface 78 of the lower edge 76 is formed with six, equally-spaced radially inward projecting lugs or tabs 80. Each ramp portion 52 includes a continuous lower edge 82 whose shape and location changes and then repeats moving from one ramp portion 52 to the next ramp portion 52 for the full circumference of this lower ring 50. Each tab 80 is positioned below this lower surface 82 with each tab 80 being positioned relative to a corresponding ramp portion 52.

This relationship between tabs 80 and lower surface 82 creates a subassembly of the two caps 24 and 26. This two-component cap subassembly typically includes a liner, or at least optionally may include the liner. However, in terms of the primary structural components, the two caps create a two-component subassembly for capping to the container neck finish 28. The combination of the inner and outer caps is not affected by the decision of whether or not to include a sealing liner such as sealing liner 35.

With the inner cap 24 and the outer cap 26 assembled together, the four projecting fingers 84 which are formed on the inner surface 86 of upper panel 74, contact the raised dome 70. The shape of tabs 80 allow the outer cap 26 to be assembled to the inner cap 24 by a snap-over or snap-on fit. The relative sizes and shapes of these two caps 24 and 26 are such that the outer cap 26 is able to press down over the inner cap 24 as is illustrated (see FIGS. 5-8). As the fingers 84 move toward raised dome 70, the tabs 80 seat beneath lower ring 50 such that each tab 80 rises against the lower surface 82 of its corresponding ramp portion 52. The outer cap 26 can initially assume any circumferential position relative to the inner cap 24 at the time of initial engagement. There are no controls or limits on the position of the outer cap 26 relative to the inner cap 24. This means that each tab 80 can assume essentially any circumferential position relative to the various sections of the corresponding ramp portion 52. Whatever the relative starting position might be for the outer cap 26 relative to the inner cap 24, this is repeated or duplicated six times in the same manner due to the equal spacings and same geometric forms with each tab 80 on its corresponding ramp portion 52.

The initial positioning of the outer cap relative to the inner cap might be influenced to some minimal or limited extent by any interference between the fingers 84 and the raised dome 70 as well as by the rotational freedom afforded to the outer cap 26 relative to the inner cap 24. For example, one possible position of initial seating would be to locate each tab 80 within a corresponding relief section 54 of one of the ramp portions 52. This particular positioning represents the position where the upper panel 74 of outer cap 26 has its maximum separation from the upper panel 46 of the inner cap 24.

The inner surface 86 of the upper panel 74 of the outer cap 26 is formed with six equally-spaced, radially-extending, torque lugs 88. Each torque lug 88 has a tapered shape radially as it extends radially inwardly and a taper circumferentially between the leading edge and the trailing edge, depending on the direction of rotation and thus the direction of travel of each torque lug 88. Each torque lug 88 is constructed and arranged to fit in-between adjacent spokes 66 for driving the inner cap 24 into threaded engagement with the neck finish 28. When the tabs 80 are rotationally oriented so as to fit in a corresponding relief section 54, the upper cap 24 is thus located axially upwardly to a location or extent such that the torque lugs 88 do not yet fit between the spokes 66. As the outer cap 26 moves in an axially downward direction there will come a point in this downward travel that the torque lugs 88 begin to enter the clearance between adjacent spokes 66. Until such time as the torque lugs 88 are capable of abutting against corresponding spokes 66, the primary driving force for the inner cap 24 by means of the outer cap 26 is not achieved. While there may be some initial rotation of the inner cap 24 by the outer cap 26 depending on the level or extent of friction with the neck finish threads, the primary driving force for advancement of the inner cap 24 onto the neck finish 28 is by means of the engagement of torque lugs 88 up against the corresponding spokes 66. Each torque lug 88 has a unique construction which is one feature of the disclosed invention. It is contemplated that the spokes 66 and the torque lugs 88 could be reversed. This would mean putting the torque lugs 88 on the inner cap 24 and the spokes 66 on the outer cap 26. In terms of driving and driven structures, either arrangement is acceptable.

The ability of the outer cap 26 to rotationally drive the inner cap 24, at least to the point of fully tightening and engaging the inner cap onto the neck finish, depends on causing the torque lugs 88 to abut up against a surface of each spoke 66 such that the rotation of outer cap 26 pushes or drives the torque lugs 88 against the spokes 66 due to their interfit. This arrangement enables the rotation of the outer cap 26 to drive the rotation of the inner cap for full threaded engagement of the inner cap 24 onto the neck finish 28.

With the inner and outer caps assembled as described and with the tabs 80 positioned below the various ramp portions 52, regardless of where those tabs may specifically be located, the torque lugs 88 are out of engagement with the spokes 66. With the manual or automated rotation of the outer cap in a clockwise direction, the first interaction between the inner cap and the outer cap begins to occur and regardless of where the individual tabs 80 may initially be positioned, there comes a point in time that those tabs contact the first ramp section 56. Assuming that the inner cap has encountered some degree of thread resistance at this point, continued rotation of the outer cap 26 will cause each tab 80 to slide along or ride along ramp section 56 pulling the outer cap in an axially downward direction. Thus, as each tab 80 rides downwardly along its corresponding ramp section 56, the outer cap travels in a downward axial direction. This tab 80 and ramp section engagement ultimately helps bring the torque lugs 88 into a position which is immediately before engagement with spokes 66. Although the four fingers 84 which are now contacting the upper surface of the raised dome 70 create a slight spring-biasing force, the level of resistance to the downward travel of the outer cap relative to the inner cap is still relatively minor and the key for proper engagement of the outer cap 26 relative to the inner cap 24 for rotationally driving the inner cap is the downward axial movement so as to position the six torque lugs 88 into an abutting relationship with the six spokes 66. The torque assistance provided by the engagement between tabs 80 and ramp portions 52 continues until just prior to contact between torque lugs 88 and spokes 66. The “just prior” reference correspond to approximately five degrees of outer cap 26 rotation. With approximately five degrees more rotation, contact between the torque lugs 88 and spokes 66 occurs. In the CCW direction the required continued rotation to achieve contact is between 20 and 30 degrees. Once the leading edge or surface of each lug 88 abuts up against the adjacent spoke 66, rotation of the outer cap 26 drives the rotation of the inner cap 24 to the extent that the inner cap may be securely threaded onto the neck finish. In an alternative embodiment the axial thickness of each torque lug 88 is substantially uniform.

Each torque lug 88 which as a unique wedge shape extending radially inwardly, also has a unique geometry relative to its axial thickness. The leading edge for each torque lug 88 for CW rotation has an axial thickness which is greater than the axial thickness of the opposite edge which is the trailing edge during CW rotation.

For CW rotation, the thicker leading edge of each torque lug 88 means less axial movement required for the outer cap toward the inner cap in order to establish abutment between the two sets of torque lugs (torque lugs 88 an spokes 66). Therefore, for rotational advancement of the inner cap by the outer cap less axial travel of the outer cap is required in order to establish torque lug engagement. This axial travel is assisted by having the tabs 80 work against the angled surface of the corresponding first ramp section 56 of each ramp portion 52.

For CCW rotation of the inner cap 24 it is necessary to establish abutment between the torque lugs 88 and spokes 66 and in this direction, a greater degree or extent of downward axial travel is required. The circumferentially tapered nature of each torque lug 88 results in this unique distinction between the amount or extent of downward axial travel which is required for CW rotation of the inner cap as contrasted to CCW rotation of the inner cap 24. In the CCW direction, the axially thinner side of each torque lug 88 is directed at its corresponding spoke 66. In order for there to be CCW driving abutment between the torque lugs 88 and spokes 66, more downward axial travel of the outer cap 26 relative to the inner cap 24 is required. This increased axial travel in turn creates a greater resistance force, albeit still moderate to slight, between the four fingers 84 and the raised dome 70. In total, the removal of the inner cap 24 from the neck finish 28 becomes a more difficult task. With a need to move the outer cap 26 farther in the axially downward direction, a slightly greater resistance force is encountered due to the engagement of the fingers 84 with the raised dome 70. This in turn requires a slightly greater force to be exerted by the user. However, the primary difference in terms of a CR structure is the amount of downward axial movement which is required of the outer cap in order to properly engage the inner cap. The degree of downward axial travel combined with the spring-biased resistive force make the opening task more difficult and it is unlikely that a child could perform these steps. Accordingly, incorporating these structures and the corresponding steps for opening the container into the construction and arrangement of the two-cap subassembly structure results in creating a two-cap, child-resistant (CR) closure.

In the removal or CCW unthreading of the inner cap 24 from the neck finish 28, there may be some assistance in the downward axial movement of outer cap 26 offered by the engagement of tabs 80 with ramp portions 52, though in the CCW direction ramp section 58 is utilized. This assistance ends with 20 to 30 degrees of cap rotation remaining before the torque lugs 88 contact the spokes 66.

Referring now to FIGS. 21-27, a second embodiment for the outer cap is illustrated, beginning with the perspective view of outer cap 100 as shown in FIG. 21. Outer cap 100 is a unitary, single-piece molded plastic component. Outer cap 100 has a sidewall 101 with a star-shaped outer surface with six similarly-shaped, outwardly-radiating, equally-spaced, axial ribs 102. This particular style of outer cap represents a second embodiment. The two outer cap embodiments disclosed herein including outer caps 26 and 100 each have inner or interior constructions which are structurally and functionally equivalent to each other. Each style of outer cap 26 and 100 has the same form, fit, function and engagement with inner cap 24. The only differences between these two outer cap embodiments involve their respective external, overall ornamental shape and appearance. Outer cap 26 is best described as having an octagonal appearance based on its eight-sided look created by faces 71. This is not a geometrically “perfect” octagon where each face 71 joins its adjacent face 71 with a pointed edge. Instead, this geometric shape is generally octagonal due to the addition of the vertical ribs 73. These ribs 73 create an ornamental styling which is distinctive and which separates adjacent faces 71.

In the case of outer cap 100, a part of its ornamental styling is to contour each outwardly radiating rib 102 with a small flatted tip 104 which is rounded on each corner 106. A convex section 108 is equally spaced between adjacent ribs 102. The sides 110 of each rib 102 extend to a small concave region 112. Adjacent concave regions 112 denote the endpoints of each corresponding convex section 108. This is a repeating pattern which occurs six times. Described as being star-shaped, this outer cap 100 sidewall 101 provides a unique and distinctive overall ornamental appearance. Further, some type of surface contouring or shaping of the outer cap provides a convenient way for any automated capping equipment to grip or chuck onto the outer cap 26, 100 for rotationally driving the inner cap 24 on to the neck finish 28. While a variety of designs might be suitable for creating this surface shaping for automated capping, the octagonal shape of outer cap 26 and the star shape of outer cap 100 are particularly distinctive. These shapes also provide a user-friendly shape for manual gripping for removal of the inner cap 24 from the neck finish and for reapplying or re-assembling the inner cap 24 onto the neck finish. The typical or standard approach for shaping of the outer surface is to use a hexagonal design.

Each rib 102 has a hollow interior 114 in lateral section and has a truncated wedge shape (see FIGS. 23 and 27). The upper surface 116 of each rib 102 is closed, while the axially lower surface of each rib 102 is open (see FIG. 27). The bottom surface 118 of outer cap 100 is substantially planar. Each rib 102 is generally aligned with each torque lug 88 such that turning or torquing forces which may be concentrated at the ribs 102 will be directed and aligned with each torque lug 88 for a more efficient force transmittal.

For convenience in understanding the inner features and construction details of outer cap 100, many of the same reference numbers which are used for outer cap 26 are also used for outer cap 100. As explained, the inner features of outer cap 26 and of outer cap 100 are essentially the same and function the same relative to their respective engagements with inner cap 24.

Referring again to FIGS. 5-8, the assembled combination of inner cap 24 and of outer cap 26 is illustrated with several different section views. The outer cap, whether outer cap 26 or outer cap 100, slides down over the inner cap 24 and establishes a snap-fit subassembly as illustrated in FIGS. 5-8. The outer cap can initially assume any circumferential position relative to the inner cap 24 as there are no controls on the position of the outer cap (26 or 100) relative to the inner cap. This means that each tab 80 (six total) can assume any circumferential position relative to the various sections 54, 56 and 58 of the corresponding ramp portion 52. Whatever relative position is the starting position of outer cap 26 or 100 relative to the inner cap, the positioning of each tab relative to the various sections is duplicated six times in the same manner, due to the equal spacing and same geometric forms, with each tab 80 on its corresponding ramp portion 52.

When the outer cap 26 or 100 is rotated in a CW direction relative to the inner cap 24 for beginning the procedure of threading the inner cap 24 onto the neck finish 28, there are various torque, friction and abutment factors which need to be assessed. At the time of initial snap-fit assembly of the two caps, it is assumed that the torque lugs 88 have not engaged the spokes 66, allowing at least initially, for the outer cap to rotate in a CW direction relative to the inner cap. Regardless of the starting rotational position of the outer cap 26 or 100 relative to the inner cap 24, CW rotation moves each tab 80 in the direction of ramp section 56 of the corresponding ramp portion 52. When the leading edge of each tab 80 contacts its corresponding ramp section 56, the two caps are able to rotate as a unit. There may be some limited or slight rotation of this two-cap subassembly, as a single unit, before the point of contact between the tabs 80 and the ramp sections 56. This depends on the level or degree of friction between the two caps and the degree or extent of any thread engagement between the inner cap 24 and the neck finish 28. Until some load is put on the inner cap 24 by the neck finish 28, rotation of the inner and outer caps as a unit is more likely.

As the tightening torque increases, there is more drag placed on the inner cap 24 and there is, as a result, a greater likelihood of the outer cap 26 or 100 rotating relative to the inner cap 24. When this occurs, each tab 80 begins to slide across and ride along its corresponding ramp section 56 in an axially downward direction. This camming action causes CW rotation of the outer cap 26 or 100 to pull the outer cap in an axial downward direction. This camming action is an assist to either the automated capping equipment or to the manual reclosing of the container by the user. When the outer cap is pulled downwardly in an axial direction close to where the (upper) torque lugs 88 abut the spokes 66 (i.e. the lower torque lugs), by the action of the tabs 80 and ramp sections 56, that engagement ends and full engagement between the lugs 88 and spokes 66 is achieved by further machine or manual movement. The abutment between these two sets of torque lugs is the manner in which the outer cap 26 or 100 rotationally drives the inner cap 24 into secure threaded engagement on the neck finish 28. The torque lugs 88 have the unique geometry in one embodiment wherein the axial height or thickness of the leading edge in a CW direction is greater than the axial height or thickness of the (opposite) leading edge in a CCW direction. The effect of this difference in axial height or thickness is to require less downward axial travel of the outer cap 26 or 100 relative to the inner cap 24 when threading the inner cap onto the neck finish 28 as contrasted to threaded removal. Threaded removal of the inner cap from the neck finish requires greater axial travel of the outer cap in a downward direction and to some extent a greater force to be applied to the outer cap in order to achieve the necessary engagement between the two sets of torque lugs. In an alternate embodiment the axial thickness of each torque lug 88 is substantially uniform.

While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes, equivalents, and modifications that come within the spirit of the inventions defined by following claims are desired to be protected. All publications, patents, and patent applications cited in this specification are herein incorporated by reference as if each individual publication, patent, or patent application were specifically and individually indicated to be incorporated by reference and set forth in its entirety herein. 

1. A closure assembly for use with a container, said closure assembly comprising: a first cap which is constructed and arranged for assembly to said container, said first cap including a sidewall having a ramp section; a second cap which is received by said first cap, said second cap including a lug which is constructed and arranged to engage said ramp section; and wherein rotation of said second cap moves said lug into engagement with said ramp section and wherein continued rotation of said second cap pulls said second cap axially downwardly.
 2. The closure assembly of claim 1 wherein said first cap further includes an abutment lug arrangement and said second cap further includes a cooperating plurality of torque lugs which are constructed and arranged for driving said first cap onto said container.
 3. The closure assembly of claim 1 wherein said ramp section is one of a plurality of ramp sections.
 4. The closure assembly of claim 3 wherein said lug is one of a plurality of lugs.
 5. The closure assembly of claim 1 wherein said first cap includes a sidewall and an abutment structure extending radially inwardly from said sidewall for cooperating with said container to help limit drop test deformation of said container.
 6. The closure assembly of claim 1 wherein said first cap further includes a first spring-biasing member and said second cap further includes a cooperating spring-biasing member which is constructed and arranged to engage said first spring-biasing member.
 7. A closure assembly for use with a container, said closure assembly comprising: a first cap which is constructed and arranged for assembly to said container, said first cap including first means for being driven onto said container; a second cap including second means for driving said first cap onto said container; and wherein one of said first means and said second means includes a torque lug having a clockwise leading edge with a first axial thickness dimension and a clockwise trailing edge with a second axial thickness dimension wherein said first axial thickness dimension is greater than said second axial thickness dimension.
 8. The closure assembly of claim 7 wherein said first means includes an abutment lug.
 9. The closure assembly of claim 8 wherein said abutment lug is one of a plurality of abutment lugs.
 10. The closure assembly of claim 7 wherein said torque lug is one of a plurality of torque lugs.
 11. The closure assembly of claim 10 wherein the number of torque lugs is equal to the number of abutment lugs.
 12. The closure assembly of claim 7 wherein said first cap includes a sidewall having a ramp section.
 13. The closure assembly of claim 12 wherein said second cap includes a lug which is constructed and arranged to engage said ramp section.
 14. The closure assembly of claim 13 wherein said ramp section is one of a plurality of ramp sections.
 15. The closure assembly of claim 13 wherein said lug is one of a plurality of lugs.
 16. The closure assembly of claim 7 wherein said first cap includes a sidewall and an abutment structure extending radially inwardly from said sidewall for cooperating with said container to help limit drop test deformation of said container.
 17. The closure assembly of claim 7 wherein said first cap includes a first spring-biasing member and said second cap includes a cooperating spring-biasing member which is constructed and arranged to engage said first spring-biasing member.
 18. A container assembly comprising: a container having a neck finish with a threaded portion and a spout portion, said neck finish defining a container opening; and a closure cap which is constructed and arranged for threaded engagement with said neck finish and for closing said container opening, said closure cap including a sidewall and an abutment protrusion extending radially inwardly from said sidewall, wherein with said closure cap assembled to said neck finish, said abutment protrusion is positioned adjacent said spout portion.
 19. The closure assembly of claim 18 further includes an outer cap which is received by said closure cap, and wherein said closure cap includes an abutment lug arrangement and said outer cap includes a cooperating plurality of torque lugs which are constructed and arranged for driving said closure cap onto said container.
 20. The container assembly of claim 18 wherein said closure cap includes a sidewall having a ramp section.
 21. The container assembly of claim 20 wherein said outer cap includes a lug which is constructed and arranged to engage said ramp section.
 22. The container assembly of claim 21 wherein said ramp section is one of a plurality of ramp sections.
 23. The container assembly of claim 22 wherein said lug is one of a plurality of lugs.
 24. The closure assembly of claim 18 wherein said closure cap further includes a first spring-biasing member and said outer cap further includes a cooperating spring-biasing member which is constructed and arranged to engage said first spring-biasing member.
 25. The closure assembly of claim 18 wherein said abutment protrusion is annular and has an inside diameter dimension and wherein said thread portion has a major thread diameter dimension which is larger than said inside diameter dimension.
 26. A closure assembly for use with a container, said closure assembly comprising: a first cap which is constructed and arranged for assembly to said container, said first cap including first means for being driven onto said container; a second cap including second means for driving said first cap onto said container; and wherein one of said first means and said second means includes a torque lug having a clockwise leading edge with a first axial thickness dimension and a clockwise trailing edge with a second axial thickness dimension wherein said first axial thickness is substantially equal to said second axial thickness. 